Removing debris from cleaning robots

ABSTRACT

A cleaning robot system including a robot and a robot maintenance station. The robot includes a robot body, a drive system, a cleaning assembly, and a cleaning bin carried by the robot body and configured to receive debris agitated by the cleaning assembly. The robot maintenance station includes a station housing configured to receive the robot for maintenance. The station housing has an evacuation passageway exposed to a top portion of the received robot. The robot maintenance station also includes an air mover in pneumatic communication with the evacuation passageway and a collection bin carried by the station housing and in pneumatic communication with the evacuation passageway. The station housing and the robot body fluidly connect the evacuation passageway to the cleaning bin of the received robot. The air mover evacuates debris held in the robot cleaning bin to the collection bin through the evacuation passageway.

CROSS-REFERENCE TO RELATED APPLICATIONS

This U.S. patent application is a continuation of and claims priority tounder 35 U.S.C. § 120 from, U.S. application Ser. No. 16/774,849, filedon Jan. 28, 2020, which is continuation of, and claims priority under 35U.S.C. § 120 from, U.S. application Ser. No. 16/544,235, filed on Aug.19, 2019, which is a continuation of, and claims priority under 35U.S.C. § 120 from, U.S. Ser. No. 15/278,772, filed on Sep. 28, 2016,which is a continuation of and claims priority to U.S. patentapplication Ser. No. 14/140,099, filed on Dec. 24, 2013 (now U.S. Pat.No. 9,492,048), which is a continuation of and claims priority to U.S.patent application Ser. No. 12/687,464, filed on Jan. 14, 2010, which isa continuation of, and claims priority to U.S. patent application Ser.No. 11/751,470, filed on May 21, 2007, which claims priority under 35U.S.C. § 119(e) to U.S. provisional patent applications 60/747,791,filed on May 19, 2006, 60/803,504, filed on May 30, 2006, and60/807,442, filed on Jul. 14, 2006. The disclosures of these priorapplications are considered part of the disclosure of this applicationand are hereby incorporated by reference in their entireties.

TECHNICAL FIELD

This disclosure relates to cleaning systems for coverage robots.

BACKGROUND

Autonomous robots are robots which can perform desired tasks inunstructured environments without continuous human guidance. Many kindsof robots are autonomous to some degree. Different robots can beautonomous in different ways. An autonomous coverage robot traverses awork surface without continuous human guidance to perform one or moretasks. In the field of home, office and/or consumer-oriented robotics,mobile robots that perform household functions such as vacuum cleaning,floor washing, lawn cutting and other such tasks have becomecommercially available.

SUMMARY

In one aspect, a cleaning robot system includes a robot and a robotmaintenance station. The robot includes a chassis, a drive systemmounted on the chassis and configured to maneuver the robot as directedby a controller in communication with the drive system, and a cleaningassembly carried by the chassis. The cleaning assembly includes acleaning assembly housing and a driven cleaning roller rotatably coupledto the cleaning assembly housing. The robot maintenance station includesa station housing and a docking platform carried by the station housingand configured to support the robot when docked. A mechanical agitatorengages the roller of the robot with the robot docked. The agitatorincludes an agitator comb having multiple teeth configured to removeaccumulated debris from the roller as the agitator comb and roller aremoved relative to one another. The robot maintenance station includes acollection bin arranged to receive and hold debris removed by themechanical agitator.

Implementations of this aspect of the disclosure may include one or moreof the following features. In some examples, the robot maintenancestation includes a station evacuation port configured to mate with therobot when the robot is received in the robot maintenance station formaintenance and a motorized vacuum pump in fluid communication with thecollection bin and the station evacuation port. The motorized vacuumpump is configured to draw air into the vacuum pump and to evacuateaccumulated debris removed by the mechanical agitator cleaning assemblyinto the collection bin. In some examples, the robot includes a downwardfacing cleaning agitator and the docking platform includes a lockingassembly configured to secure the received robot to the platform so thatthe mechanical agitator cleaning assembly does not force the robot fromthe platform. The mechanical agitator cleaning assembly may include oneor more blades configured to cut accumulated filaments off the roller.The mechanical agitator cleaning assembly may include an actuatorconfigured to move the agitator of the docked robot. The cleaning robotsystem may include a vacuum assembly configured to evacuate cutfilaments off the mechanical agitator cleaning assembly.

In another aspect, a cleaning robot system includes a robot and a robotmaintenance station. The robot includes a chassis, a drive systemmounted on the chassis and configured to maneuver the robot as directedby a controller in communication with the drive system, and a cleaningassembly carried by the chassis. The cleaning assembly includes acleaning assembly housing and a driven cleaning roller rotatably coupledto the cleaning assembly housing. The robot includes a cleaning bincarried by the chassis. The robot maintenance includes a station housingconfigured to receive the robot for maintenance. The station housingdefines a blower port and an evacuation port spaced from the blowerport. The station blower port and the evacuation port are both arrangedto be exposed to the robot cleaning bin when the robot is received inthe maintenance station for maintenance. The robot maintenance includesa collection bin carried by the station housing and in fluidcommunication with the evacuation port and an air pump that blows airthrough the station blower port into the cleaning bin while drawing airthrough the station evacuation port and evacuating debris from the robotcleaning bin into the collection bin.

Implementations of this aspect of the disclosure may include one or moreof the following features. In some examples, the robot maintenancestation includes a mechanical agitator cleaning assembly arranged toengage a driven cleaning agitator of the cleaning head. The mechanicalagitator cleaning assembly includes an agitator comb having multipleteeth configured to remove accumulated debris from the driven cleaningagitator as the agitator comb and driven cleaning agitator are movedrelative to one another. A collection bin receives accumulated debrisfrom the agitator removed by the mechanical agitator cleaning assembly.The robot cleaning bin may be removable from the robot and thecollection bin may be removable from the maintenance station. In someimplementations, the cleaning head includes a vacuuming cleaning headconfigured to evacuate debris from the floor into the cleaning bin. Insome implementations, the cleaning head includes a sweeping cleaninghead configured to agitate debris from the floor and sweep the debrisinto the cleaning bin. The maintenance station may include a lockingassembly configured to secure the robot with the station blower port andthe station evacuation ports. The station blower port and the stationevacuation ports are substantially sealed to the cleaning bin when therobot is received in the maintenance station for maintenance. In someimplementations, the robot includes an internal bin maintenance sensorthat monitors the contents of the robot cleaning bin for a maintenancecondition. The controller of the robot causes the robot to begin seekingthe maintenance station in order to dock and evacuate the robot cleaningbin in response to the maintenance condition.

In another aspect, a cleaning robot system includes a robot and a robotmaintenance station. The robot includes a chassis, a drive systemmounted on the chassis and configured to maneuver the robot as directedby a controller in communication with the drive system, a cleaning headcarried by the chassis and including a mechanical agitator, and acleaning bin carried by the chassis. The robot maintenance stationincludes a docking platform configured to support the robot with therobot docked for maintenance and an agitator comb arranged to engage theagitator of the docked robot and configured to remove accumulated debrisfrom the agitator as the agitator comb and agitator are moved relativeto one another. The robot maintenance station includes a collection bindisposed more than one foot above the docking platform and an air pumpthat pumps air past the agitator comb. The pumped air motivates debrisremoved by the agitator comb into the collection bin.

Implementations of this aspect of the disclosure may include one or moreof the following features. In some examples, the air pump also moves aflow of air that evacuates debris from the robot cleaning bin. Themechanical agitator may include one or both of rotating bristle brushmembers and a rotating pliable beater members. The agitator comb mayinclude one or both of rotating bristle brush members and a rotatingpliable beater members. In some examples, the agitator comb includesblades for severing filaments among the debris. In other examples, theagitator comb includes slicker teeth for severing filaments among thedebris. The agitator comb may be rotated relative to the mechanicalagitator.

In yet another aspect, a cleaning robot system includes a robot and arobot docking station. The robot includes a chassis, a drive systemmounted on the chassis and configured to maneuver the robot as directedby a controller in communication with the drive system, a drivencleaning head rotatably carried by the chassis, and a cleaning bincarried by the chassis and configured to receive debris from thecleaning head during cleaning. The robot docking station includes adocking station housing configured to receive the robot in a dockedconfiguration for robot maintenance, a debris collection bin, and amotorized vacuum pump that draws air and debris from the robot cleaningbin to deposit the debris into the debris collection bin. The collectionbin and vacuum pump are removable from the docking station housing as anassembly that also includes a graspable handle and forms a manuallyoperable vacuum cleaner.

Implementations of this aspect of the disclosure may include one or moreof the following features. In some examples, the housing of the dockingstation fluidly connects the motorized vacuum pump to the robot cleaninghead to evacuate the robot cleaning head into the collection bin of themanually operable vacuum cleaner. In some implementations, the housingof the docking station fluidly connects the a vacuum cleaner cleaninghead of the docking station to the robot cleaning head to evacuate therobot cleaning bin into the collection bin of the manually operablevacuum cleaner. In some examples, the robot cleaning head includes amechanical agitator and the vacuum cleaner cleaning head includes atleast one agitator comb. The housing of the docking station mechanicallyconnecting the agitator comb of the vacuum cleaner cleaning head to themechanical agitator of the robot cleaning head to remove accumulateddebris from the mechanical agitator. The mechanical agitator may includeone or both of rotating bristle brush members and a rotating pliablebeater members. The agitator comb may include one or both of rotatingbristle brush members and a rotating pliable beater members.

The details of one or more implementations of the disclosure are setfourth in the accompanying drawings and the description below. Otherfeatures, objects, and advantages will be apparent from the descriptionand drawings, and from the claims.

DESCRIPTION OF DRAWINGS

FIG. 1 is a perspective view of a maintenance station and a coveragerobot.

FIG. 2 is a perspective view of a maintenance station.

FIG. 3 is a perspective view of a maintenance station and a coveragerobot.

FIGS. 4-5 are exploded views of maintenance stations.

FIG. 6A is a top view of a coverage robot.

FIG. 6B is a bottom view of a coverage robot.

FIG. 7 is a side view of a locking assembly.

FIG. 8 is a perspective view of a cleaning assembly of a maintenancestation.

FIG. 9 is a perspective view of a coverage robot with bin evacuationports.

FIGS. 10A-10B are side views of a coverage robot docking with amaintenance station.

FIG. 11A is a perspective view of a coverage robot docking with amaintenance station.

FIG. 11B is a side view of a coverage robot docking with a maintenancestation.

FIG. 12A is a perspective view of a coverage robot docking with amaintenance station.

FIG. 12B is a side view of a coverage robot docking with a maintenancestation.

FIG. 12C is a schematic side view of a coverage robot having a cleaningbin cover panel operating to clean a floor.

FIG. 12D is a schematic side view of a coverage robot having a cleaningbin cover panel docked with a maintenance station.

FIG. 13A is a perspective view of a coverage robot docking with amaintenance station.

FIG. 13B is a side view of a coverage robot docking with a maintenancestation.

FIG. 14A is a perspective view of a coverage robot docking with amaintenance station.

FIG. 14B is a perspective view of a coverage robot docking with amaintenance station.

FIG. 14C is a side view of a coverage robot docking with a maintenancestation.

FIG. 15A is a perspective view of a coverage robot docking with amaintenance station.

FIG. 15B is a side view of a coverage robot docking with a maintenancestation.

FIG. 16A is a perspective view of a coverage robot docking with amaintenance station.

FIG. 16B is a side view of a coverage robot docking with a maintenancestation.

FIG. 17A is a perspective view of a coverage robot docking with amaintenance station.

FIG. 17B is a perspective view of a coverage robot docking with amaintenance station.

FIG. 17C is a side view of a coverage robot docking with a maintenancestation.

FIG. 18A is a top view of a roller cleaning system.

FIG. 18B is a perspective view of a roller cleaning system.

FIG. 18C is a side sectional view of a roller cleaning tool.

FIG. 18D is a side view of a roller cleaning tool.

FIGS. 19A-19F are schematic views a coverage robot docking with amaintenance station for servicing.

FIGS. 20A-21B are perspective views of maintenance stations.

FIGS. 22A-22B are side views of maintenance stations and docked coveragerobots.

FIGS. 23A-24B are perspective views of hand held maintenance stations.

FIG. 25A is a perspective view of a maintenance station with a trash canportion.

FIG. 25B is a schematic view of a maintenance station with a trash canportion.

FIGS. 26A-27B are perspective views a maintenance station connectible toa house central vacuum system.

FIGS. 27A-27C are schematic views of an upright vacuum cleanerconfigured to evacuate a coverage robot bin.

Like reference symbols in the various drawings indicate like elements.

DETAILED DESCRIPTION

Referring to FIGS. 1-5, a maintenance station 100 for maintaining arobotic cleaner 10 includes a station housing 120 and a platform 122 onwhich the robot 10 is supported during servicing. In some examples, themaintenance station 100 defines an inner bay 124 enclosing the platform122 for housing the robot 10 during servicing or for storage. A door 130pivotally attached near the bottom of the maintenance station 100encloses an opening 126 into the inner bay 124. The door 130 may be usedas a ramp that the robot 10 maneuvers up to reach the platform 122(e.g., as shown in FIG. 3). In some examples, the platform 120 includesan elevator configured to elevate the robot 10 up into the station 100to a servicing position. The elevator may be a timing belt, four-barlinkage, walking beam, or other mechanical device. The elevator is mostappropriate for robots having a brush or other mechanical cleaningimplement primarily accessible via a lower surface of the robot. In sucha case, the elevator elevates the robot 10 by a sufficient amount (e.g.,at least one brush diameter, and preferably two brush diameters) suchthat mechanical servicing members and their driving apparatus can workbeneath the robot. In examples where the platform 120 is not enclosed,e.g. FIG. 1, the platform 122 is inclined extending upward from theground, allowing the robot 10 to maneuver up the platform 120 to aservicing position.

The maintenance station 100 may include a user interface 140 disposed onthe housing 120. In some implementations, the user interface 140 isremovably attachable to the housing 120 and configured to wirelessly(e.g., via radio frequencies—“RF”- or infrared emissions—“IR”)communicate to a communication module 1400 on the maintenance station100, and/or to a compatible communication facility on the robot 10. Thecommunication module 1400 includes an emitter 1403 and a detector 1405configured to emit and detect RF and/or IR signals, which are preferablymodulated and encoded with information. Information to be transmittedfrom the communication module 1400 includes directional signals having adefined area of effect or direction (e.g., homing signals detectable bythe robotic cleaner 10 and used to locate and/or drive towards thesource of the homing signal), and command signals having encoded contentincluding remote commands (e.g., command or cleaning schedulinginformation detectable by the robot 10 or navigation devices for therobot 10). The user interface 140 includes buttons 142 and a display 144allowing a user to input commands or instructions which are thenprocessed by a controller 170 of the maintenance station 100 (or by therobot 10). The display 144 alerts the user to the status of themaintenance station 100 and provides visual feedback in response tocommands and instructions inputted by the user. Preferably, the userinterface 140 is removable and remotely operable external from themaintenance station 100 using the communication module 1400. In someexamples, the user interface 140 is permanently installed on themaintenance station 100. Examples of indicators and controls that may beincluded on the user interface 140 include power on/off, a station binfull indicator, indicator for the robot on carpet or hardwood (allowingorbit self-adjusting to the surface demands), control to clean only theroom the robot 10 or station 100 is placed in, return to stationcontrol, pause/resume cleaning, zone control, and scheduling.

The maintenance station 100 includes a collection bin 150 attached tothe housing 120. The collection bin 150 is different from a (sweeper,vacuum, or combination) cleaner bin 50 located in the robot 10 in thatits primary purpose is to collect and accumulate from the cleaner bin ofa mobile robot 10. The collection bin 150 is three to ten times thevolumetric capacity of the mobile robot bin 50. As shown in the examplesillustrated in FIGS. 1-5, the collection bin 150 may be integral withthe housing 120 (FIG. 1), removably attached to a top portion of thehousing 120 to be disengaged substantially parallel to the ground (FIG.3), removably attached to a front or overhanging portion of the housing120 to be disengaged substantially parallel to the ground fromunderneath the overhang (FIG. 4), or removably attached to the top ofthe housing to be disengaged in a vertical direction (FIG. 5).

In the example shown in FIG. 5, the cleaning bin 150 is received by abin receptacle 152 defined by the housing 120. A station cover 110pivotally attached to the housing 120 encloses the bin receptacle 152.In some cases, the top of the housing 120 defines the bin receptacle 152and receives the station cover 110. In other cases, the rear or side ofthe housing 120 defines the bin receptacle 152 and receives the stationcover 110. In some examples, the station cover 110 is unhinged from thehousing 120 for servicing the bin 150.

In some implementations, the maintenance station 100 includes acommunication port 180. The port 180 may be installed along a bottomside edge of the maintenance station 100 so as not to interfere withnearby internal components. Example configurations of the port 180include RS232 serial, USB, Ethernet, etc. The primary purpose of thecommunication port is (i) permitting “flashing” of microcontroller codefor controlling the maintenance station 100 and (ii) permittingaccessories to the maintenance station 100 (such as an auxiliary brushcleaner discussed herein) to be connected to and controlled along withthe maintenance station 100 and robot 10.

Referring to FIG. 3, the maintenance station 100 includes a binconnecter 112 configured to mate with a corresponding bin connector 154on the collection bin 150. The bin connectors 112, 154 provide a flowpath for evacuating debris from the robot bin 50 to the maintenancestation collection bin 150.

Referring to FIGS. 6A-6B, the autonomous robotic cleaner 10 includes achassis 31 which carries an outer shell 6. FIG. 6A illustrates the outershell 6 of the robot 10 connected to a bumper 5. The robot 10 may movein forward and reverse drive directions; consequently, the chassis 31has corresponding forward and back ends, 31A and 31B respectively. Theforward end 31A is fore in the direction of primary mobility and in thedirection of the bumper 5; the robot 10 typically moves in the reversedirection primarily during escape, bounces, and obstacle avoidance. Acleaning head assembly 40 is located towards the middle of the robot 10and installed within the chassis 31. The cleaning head assembly 40includes a main brush 60 and a secondary parallel brush 65 (either ofthese brushes may be a pliable multi-vane beater or a have pliablebeater flaps 61 between rows of brush bristles 62). A battery 25 ishoused within the chassis 31 proximate the cleaning head 40. In someexamples, the main 65 and/or the secondary parallel brush 60 areremovable. In other examples, the cleaning head assembly 40 includes afixed main brush 65 and/or secondary parallel brush 60, where fixedrefers to a brush permanently installed on the chassis 31.

Installed along either side of the chassis 31 are differentially drivenwheels 45 that mobilize the robot 10 and provide two points of support.The forward end 31A of the chassis 31 includes a caster wheel 35 whichprovides additional support for the robot 10 as a third point of contactwith the floor and does not hinder robot mobility. Installed along theside of the chassis 31 is a side brush 20 configured to rotate 360degrees when the robot 10 is operational. The rotation of the side brush20 allows the robot 10 to better clean areas adjacent the robot's sideby brushing and flicking debris beyond the robot housing in front of thecleaning path, and areas otherwise unreachable by the centrally locatedcleaning head assembly 40. A removable cleaning bin 50 is locatedtowards the back end 31B of the robot 10 and installed within the outershell 6.

Referring to FIG. 7, a lock assembly 260 may be installed on theplatform 122 for securing the robotic cleaner 10 to the platform 122 viaa corresponding lock assembly 72 on a bottom side of robot chassis 31.Referring to FIG. 7, in some implementations, a clip catch 74 isinstalled on the bottom of the robot chassis 31 and configured to matewith a clip 262 on the maintenance station 100. The clip 262 engages thecatch 74 to lock the robot 10 in place during servicing of the bin 50and/or brushes or rollers 60, 65. In order to service brushes or rollers60, 65 in particular, if the robot 10 is elevated and the brushes 60, 65available for service at the bottom of the robot 10, the upward force ofrotating, reciprocating, or traversing cleaning tools as discussedherein may lift a relatively light weight robot (e.g., a 3-15 lb robotwill be lifted by this much upward force). Accordingly, when the robot10 is elevated or brought to a brush service position, the matinglocking assemblies hold the robot 10 against this upward force.Referring to FIG. 8, in some implementations, the lock assembly 260includes two protrusions or pegs 264 received by the robot lock assembly72 to anchor the robot 10. The lock assembly 260 may providecommunication (e.g. via the pegs 264) between the robot 10 and themaintenance station 100.

Once contacts on the underside of the robotic cleaner 10 connect withthe contacts 264 on the platform 122, the maintenance station 100 mayemit a command signal to the robotic cleaner 10 to cease driving.Alternatively, the robot's microcontroller and memory may exerciseprimary control of the maintenance station and robot combination. Inresponse to the command signal, the robotic cleaner 10 stops drivingforward and emits a return signal to the maintenance station 100indicating that the drive system has shut down. The maintenance station100 then commences a locking routine that mobilizes the locking assembly260 to lock and secure the robotic cleaner 10 to the platform 122.Again, alternatively, the robot 10 may command the maintenance stationto engage its locks.

Referring to FIG. 8, a cleaning assembly 300 is carried by the housing120 and includes a bin evacuation (vacuuming) assembly 400 and amechanical brush or roller cleaning assembly 500. The bin evacuationassembly 400 is secured to the platform 122 and positioned to engage anevacuation port assembly 80 of the cleaning bin 50, as shown in FIG. 9.The evacuation port assembly 80 may include a port cover 55. In someimplementations, the port cover 55 includes a panel or panels 55A, 55Bwhich may slide (or be otherwise translated) along a side wall of thechassis 31 and under or over side panels of the outer shell 6 to openthe evacuation port assembly 80. The evacuation port assembly 80 isconfigured to mate with the corresponding evacuation assembly 400 on themaintenance station 100. In some implementations, the evacuation portassembly 80 is installed along an edge of the outer shell 6, on a topmost portion of the outer shell 6, on the bottom of the chassis 31, orother similar placements where the evacuation port assembly 80 has readyaccess to the contents of the cleaning bin 50. In some implementations,the evacuation assembly 400 includes a manifold 410 defining a pluralityof evacuation ports 80A, 80B, 80C that are distributed across the entirevolume of the cleaning bin 50, e.g., center evacuation port 480A and twoside evacuation ports 480B and 480C on either side. The evacuation ports480A, 480B, 480C on the station 100 are configured to mate withcorresponding evacuation ports 80A, 80B, 80C on the robot cleaning bin50, preferably with a substantially air-tight vacuum seal. In someexamples, the evacuation port assembly 80 is disposed on a top or bottomside of the cleaning bin 50. While evacuating from a top-side evacuationport assembly 80, a suction placed on at least one of the evacuationports 80A, 80B, 80C tends to first draw loosely packed material off atop layer of debris, followed by successive layers of debris. Binsymmetry may aid bin evacuation.

Referring to FIGS. 10A-10B, when the robot 10 maneuvers onto theplatform 122 to dock with the station 100 for servicing, the robot 10 isguided or aligned so that the evacuation port assembly 80 on the robotcleaning bin 50 engages the station evacuation assembly 400. The robot10 may be guided by a homing signal, tracks on the platform 122, guiderails, a lever, or other guiding devices. The evacuation assembly 400disengages the port cover 55 on the robot cleaning bin 50, in someexamples, when the robot 10 docks with the station 100. In someimplementations, each evacuation port 480A, 480B, 480C draws debris outof the cleaning bin 50. In other implementations, one or more evacuationports 480A, 480B, 480C blow air into the cleaning bin 50, while one ormore evacuation ports 480A, 480B, 480C draw debris out of the cleaningbin 50. For example, evacuation ports 480B and 480C blow air into thecleaning bin 50, while evacuation port 480A draws debris out of thecleaning bin 50. The evacuation manifold 410 is connected to a debrisline that directs evacuated debris to the station bin 150. A filter 910may be disposed at the intake of a vacuum 900 that provides suction forthe evacuation assembly 400.

Referring to FIGS. 11A-12B, in some implementations, the robot 10includes a port cover 55 accessible on a top side on the robot 10providing access to the cleaning bin 50. FIGS. 11A-11B illustrate anexample where the robot 10 docks with the forward chassis end 31A facingtoward the station 100. Upon docking, either the robot 10 or the station100 opens the port cover 55 to evacuate debris up out of the top of therobot bin 50 and into the station bin 150. FIGS. 12A-12B illustrate anexample where the robot 10 docks with the rear chassis end 31B facingtoward the station 100 to evacuate debris up out of the top of the robotbin 50 and into the station bin 150. In both examples, the robot 10maneuvers under a portion of the station 100, which gains access to atop portion of the robot bin 50. As shown in FIG. 12C, a robot 10 cleansalong the floor in the manner described herein, driven and supported bywheels 35, 45. Within the outer shell 6, the primary brush 60 turns in adirection opposite to forward travel, and the parallel secondary brush65 catches debris agitated by the primary brush 60 and ejects it up andover the primary brush 60 into the bin 50. A squeegee vacuum may trailthe primary brush 60, part of the bin 50. A panel 55, in thisconfiguration, may cover the top of the brushes, with an angled surfacewithin the chassis 31 or panel 55 to angle debris from the brushes 60,65 into the bin 50. Referring to FIG. 12C, in some instances, the bin 50includes a bin-full detection system 700 for sensing an amount of debrispresent in the bin 50. In one implementation, the bin-full detectionsystem includes an emitter 755 and a detector 760 housed in the bin 50and in communication with the controller 49.

As shown in FIG. 12D (a variation upon FIGS. 11B and 12B), the robot 10may follow a platform 122 into the maintenance station 100. Once withinor engaged with the maintenance station 100, the panel 55 is moved asideto expose at least the primary brush 60 (to expose any brushes which mayaccumulate filaments or fuzz, including bristle type brushes). Themaintenance station 100 may lower, or locate in predetermined positions,brush-cleaning brush or beater 530 and optionally parallel brush orbeater 535. The brush cleaning member/mechanism 530 engages the primarycleaning brush 65, and is driven by a motor (not shown) in themaintenance station 100 (or uses the brush 60 motor) to clean the brush60. The optional parallel brush 535 may catch the debris or filamentsagitated by the brush cleaning brush 530 and eject them up and over thebrush 530 to the collection bin 150 in the maintenance station 100. Asdiscussed herein, the collection bin 150 may be a vacuum bin, andinclude a vacuum filter 910 removable with the bin; may engage themaintenance bin via ports 154, 112, and be evacuated by a vacuum motor900 in the maintenance station 100. In the configuration shown in FIG.12D, the vacuum 900 is a high powered vacuum (e.g., 6-12 amp) that pullsair through the filter 910, through the collection bin 150, over andthrough the brushes 530, 535, and optionally directly or diverted fromthe cleaning bin 30 of the robot 10. Optionally, the remaining areas ofthe robot 10 (e.g., circuit board areas) may benefit from evacuation aswell, and are not sealed from the vacuum.

Referring to FIGS. 13A-16B, in some implementations, the robot 10maneuvers onto an inclined platform 122 of the station 100 to provideaccess to an underside of the robot 10 for servicing the cleaning bin50. The station 100 evacuates debris down out of the robot bin 50 andinto the station bin 150. FIGS. 13A-13B illustrate an example where therobot 10 docks with the station 100 with the forward chassis end 31Afacing forward on the platform 122 and debris is evacuated down out ofthe bottom of the robot bin 50 into the station bin 150. FIGS. 14A-14Cillustrate an example where the robot 10 docks with the station 100 withthe rear chassis end 31B facing forward on the platform 122 and debrisis evacuated down out of the bottom of the robot bin 50 into the stationbin 150. FIGS. 15A-15B illustrate an example where the robot 10 dockswith the station 100 with the rear chassis end 31B facing forward on theplatform 122 and debris is evacuated down out of the bottom of the robotbin 50 and then up into the station bin 150. FIGS. 16A-16B illustrate anexample where the robot 10 docks with the station 100 with the forwardchassis end 31A facing forward on the platform 122 and debris isevacuated down out of the bottom of the robot bin 50 and then up intothe station bin 150.

Referring to FIGS. 17A-17C, in some implementations, the robot 10 dockswith the rear chassis end 31B facing toward the station 100 to evacuatedebris out of the rear of the robot bin 50 and into the station bin 150.The station bin 150 may be located above, below, or level with the robotbin 50.

In any of the examples described, the evacuation station 100 mayevacuate the robot bin to with a sweeper device (e.g. rotating bush orsweeper arm), in conjunction with or instead of vacuuming. Inparticular, the maintenance station mechanical service structuresillustrated in FIGS. 8, 12D, 18A-18C may mechanically service brushes,flappers, beaters, or other rotating or reciprocating cleaning agitatorsin situ in the robot 10 from the top, bottom, or sides of the robot 10,and/or with the cleaning agitators being articulated to protrude fromthe robot 10; and/or wholly removed from the robot 10 as a cartridgeunit or as a plain brush; and/or with the mechanical service structuresbeing stationary or articulated to intrude into the shell 6 of the robot10.

Referring to FIGS. 8 and 18A-18D, in some implementations, the platform122 defines an opening 123 which provides access for the roller cleaningassembly 500 to the cleaning head assembly 40 of the robot 10 forservicing the main 65 brush and/or the secondary brush 60 (optionallyincluded or the robot 10). The roller cleaning assembly 500 includes adriven linear slide guide 502 carrying a cleaning head cleaner 510and/or a trimmer 520. In some examples, the driven linear slide guide502 includes a guide mount or rail follower 503 carrying the cleaninghead cleaner 510 and slidably secured to a shaft or rail 504. The railfollower 503 is driven by a motor 505 via a belt (as shown), lead screw,rack and pinion, or any other linear motion drive. A rotator 530 rotatesthe roller 60, 65 during cleaning. The maintenance station 100 includesa controller 1000 in communication with the communication module 1400and the cleaning assembly 300 that may control the agitation andcleaning processes, set an order of events, and otherwise drive themechanical and vacuum cleaning facilities described herein in anappropriate order.

The cleaning head cleaner 510, in some examples, includes a series ofteeth or combs 512 configured to strip filament and debris from a roller60, 65. In some implementations, the cleaning head cleaner 510 includesone or more flat, semi-tubular or quarter-tubular tools 511 having teeth512, dematting rakes 514, combs, or slicker combs. The tubular tool 511may be independently driven by one or more servo, step or other motors505 and transmissions (which may be a belt, chain, worm, ball screw,spline, rack and pinion, or any other linear motion drive). In someexamples, the roller 60, 65 and the cleaning head cleaner 510 are movedrelative to one another. In other examples, the cleaning head cleaner510 is fixed in place while the roller 60, 65 is moved over the cleaninghead cleaner 510.

The roller 60, 65 is placed adjacent the cleaning head cleaner 510,either while in situ in the robot 10, in a removable cleaning headcartridge 40, or as a stand alone roller 60, 65 removed from the robot10. If the roller 60, 65 is part of a removable cleaning head cartridge40, the cleaning head cartridge 40 is removed from the robot 10 andplaced in the station 100 for cleaning. Once the roller 60, 65 ispositioned in the station 100 for cleaning, the station 100 commences acleaning routine including traversing the cleaning head 510 over theroller 60, 65 such that the teeth 512, dematting rakes 514, combs, orslicker combs, separately or together, cut and remove filaments anddebris from the roller 60, 65. In one example, as the cleaning head 510traverses over the roller 60, 65, the teeth 512 are actuated in arotating motion to facilitate removal of filaments and debris from theroller 60, 65. In some examples, an interference depth of the teeth 512into the roller 60, 65 is variable and progressively increases with eachsubsequent pass of the cleaning head 510.

FIG. 18C illustrates an example semi-tubular tool 600 having first andsecond ends, 601 and 602 respectively. The first end 601 of the tool 600defines a semi-bell shaped opening 605. The semi-tubular tool 600includes teeth 610 disposed along an inner surface 603. In someimplementations, the semi-tubular tool 600 includes trailing comb teeth620, which may grab and trap remaining loose strands of hair orfilaments missed or released by the teeth 610. The trailing comb teeth620 may be more deformable, deeper, thinner, or harder (and vice versa)than the teeth 250 to scrape or sweep exterior surfaces of the roller60.

FIG. 18D demonstrates a semi-tubular tool 600 in use. The semi-bellshaped opening 605 of the tool 600 is applied toward the roller 60having bristles 61, facilitating entry of the roller 60 into the tool60. In cases where the roller 60 includes inner pliable flaps 62, thesemi-bell shaped opening 605 is at least slightly larger in diameterthan the axial extension or spooling diameter of inner pliable flaps 62.Along the length of the tool 60, the tool 60 narrows to a constant, maindiameter, and the inner pliable flaps 62 are deformed by the main innerdiameter of the tool 600. In some implementations, the tool 600 definesinner protrusions 615 to deform the bristles 61 and/or the inner pliableflaps 62. Any filaments or hairs collected about the spooling diameterare positioned where they will be caught by the approaching teeth 610(which extend into the tool 60 to a point that is closer to the rolleraxis than the undeformed flaps 62, but farther away than an end cap 63).Two kinds of teeth 610 are shown in FIG. 18D, triangular forward cantedteeth 610A with a straight leading profile, and shark-tooth forwardcanted teeth 610B with a curved entry portion or hook, e.g., a U orJ-shaped profile on the leading edge of each tooth, opening toward theroller 60 in the direction of tube application. Either or both teeth610A, 610B may be used, in groups or otherwise. After one or more passesof the tool 600 over the roller 60, the station 100 retracts the tool600 to a position for tool cleaning and evacuation of debris off thetool 600 and into the station bin 150.

Referring back to FIG. 1B, in some implementations, the robot 10includes a communication module 90 installed on the bottom of thechassis 31. The communication module 90 provides a communication linkbetween the communication module 1400 on the maintenance station 100 andthe robot 10. The communication module 90 of the robot 10, in someinstances, includes both an emitter and a detector, and provides analternative communication path while the robot 10 is located within themaintenance station 100. In some implementations, the robot 10 includesa roller full (brush service) sensor assembly 85 installed on eitherside of and proximate the cleaning head 40, with a detection pathextending along the length of the brush or roller to detectaccumulations of filaments or fuzz along the length of the brush orroller. The roller full (brush service) sensor assembly 85 provides userand system feedback regarding a degree of filament wound about the mainbrush 65, the secondary brush 60, or both. The roller full sensorassembly 85 includes an emitter 85A for emitting modulated beams and adetector 85B configured to detect the beams. The emitter 85A anddetector 86B are positioned on opposite sides of the cleaning headroller 60, 65 and aligned to detect filament wound about the cleaninghead roller 60, 65. The roller full sensor assembly 85 includes a signalprocessing circuit configured to receive and interpret detector output.In some examples, the roller full sensor system 85 detects when theroller 60, 65 has accumulated filaments, when roller effectiveness hasdeclined, or when a bin is full (as disclosed in U.S. Provisional PatentNo. 60/741,442, filed Dec. 2, 2005, and herein incorporated by referencein its entirety), trigging the return of the robot to a maintenancestation 100, as described herein, and notifying the robot 10 ormaintenance station 100 that the brush(es) 60, 65 require service orcleaning. As discussed herein, a head cleaning tool 600 configured toclear debris from the cleaning roller 60, 65 in response to a timer, areceived command from a remote terminal, the roller full sensor system85, or a button located on the chassis/body 31 of the robot 10.

Once a cleaning cycle is complete, either via the roller full sensorsystem 85 or visual observation, the user can open the wire bale andpull out the roller(s) 60, 65. The roller(s) 60, 65 can then be wipedclean off hair and inserted back in place.

Referring to FIGS. 19A-F, in some implementations, the robot 10 includesa removable cleaning head cartridge 40, which includes at least onecleaning roller 60, 65. When the robot 10 determines that cleaning heador cleaning head cartridge 40 needs servicing (e.g. via a bin service,brush service, or roller full detection system 85, a bin full detectionsystem, or a timer) the robot 10 initiates a maintenance routine. StepS19-1, illustrated in FIG. 19A, entails the robot 10 approaching thecleaning station 100 with the aid of a navigation system. In oneexample, the robot 10 navigates to the cleaning station 100 in responseto a received homing signal emitted by the station 100. Docking,confinement, home base, and homing technologies discussed in U.S. Pat.Nos. 7,196,487; 7,188,000 or U.S. Patent Application Publication No.20050156562 are suitable homing technologies. In step S19-2, illustratedin FIG. 19B, the robot 10 docks with the station 100. In the exampleshown, the robot 10 maneuvers up a ramp 122 and is secured in place by alocking assembly 260. In step S19-3, illustrated in FIG. 19C, the dirtycartridge 40A is automatically unloaded from the robot 10, either by therobot 10 or the cleaning station 100, into a transfer bay 190 in thecleaning station 100. In some examples, the dirty cartridge 40A ismanually unloaded from the robot 10 and placed in the transfer bay 190by a user. In other examples, the dirty cartridge 40A is automaticallyunloaded/discharged from the robot 10, but manually placed in thetransfer bay 190 by the user. In step S19-4, illustrated in FIG. 19D,the cleaning station 100 exchanges a clean cartridge 40B in a cleaningbay 192 with the dirty cartridge 40A in the transfer bay 190. In oneexample, the cartridges 40A, 40B are moved by automation in the station100. In another example, the transfer bay 190 and associated dirtycartridge 40A is automatically swapped with the cleaning bay 192 andassociated clean cartridge 40B. In step S19-5, illustrated in FIG. 19E,the cleaning station 100 automatically transfers the clean cartridge 40Binto the robot 10. In some examples, the user manually transfers theclean cartridge 40B from the transfer bay 190 into the robot 10. In stepS19-6, illustrated in FIG. 19F, the robot 10 exits the station 100 andmay continue a cleaning mission. Meanwhile, the dirty cartridge 40A inthe station 100 is cleaned. The automated cleaning process may be slowerthan by hand, require less power, clean more thoroughly, and performquietly (e.g. by taking many slow passes over the roller 60, 65).

Referring to FIGS. 20A-25B, a maintenance station 1100 evacuates therobot collection bin 50, but does not perform maintenance on thecleaning head assembly 40. FIGS. 20A-21B illustrate examples of themaintenance station 1100 including a station base 1102 and a handheldvacuum 1110 removably secured to the station base 1102. The base 1102includes an evacuation assembly 400 in communication with the handheldvacuum 1110, while attached thereto. The handheld vacuum 1110 having ahandle 1111 either manually (e.g. via operator control) or automaticallyevacuates the robot bin 50, once the robot 10 docks with the maintenancestation 1100. The station base 1102 may include a locking assembly 260for securing and/or communicating with the robot 10. While detached fromthe station base 1102, the handheld vacuum 1110 functions as a normalvacuum cleaner. In some examples, the handheld vacuum 1110 includes avacuum hose 1112 and/or a cleaning head 1105 for cleaning surfaces. Thestation base 1102 may defines receptacles 1104 for receiving and storingvacuum attachments 1114. In some implementations, the station base 1102includes a separate station bin 1150 from the handheld vacuum 1110.

FIGS. 22A-24B illustrate an example of the maintenance station 1100including a handheld vacuum 1110 configured to be received directly bythe bin 50 of the robot 10 for evacuation of debris out of the bin 50and into the station bin 1150. In FIG. 21A, the maintenance station 1100includes a station base 1102. In FIGS. 21B-24B, the maintenance station1100 does not include a station base 1102. Instead, the handheld vacuum1110 either supports itself or is held by a user during bin evacuation.A house attachment 1120 may be used to aid bin evacuation.

FIGS. 25A-25B illustrates an example of a maintenance station 1200configured as a trash container or other utility “furniture”. Themaintenance station 1200 includes a docking portion 1202 and a trash canportion 1210 including a trash can lid 1212. The docking portion 1202 isconfigured to evacuate debris from the docked robot bin 50 directly intoa trash receptacle of the trash can portion 1210. The trash receptacleis accessible by the user for depositing other refuse as well. In someimplementations, the trash can portion 1210 includes a trash compactorthat periodically (or upon user command) compacts refuse in the trashcan portion 1210. In such a case, the robot 10 may follow a platform 122into a maintenance station 100 that includes a trash can portion 1210(in this case, the maintenance station 100 may also be wholly enclosedin or part of the trash can 1200). Once within or engaged with themaintenance station 100, the panel 55 is moved aside to expose at leastthe primary brush 60 (to expose any brushes which may accumulatefilaments or fuzz, including bristle type brushes). The docking portion1202 may lower, or locate in predetermined positions, brush-cleaningbrush or beater 530. The brush cleaning member/mechanism 530 engages theprimary cleaning brush 65 of the robot 10, and is driven by a motor (notshown) in the maintenance station 100. The debris or filaments agitatedby the brush cleaning brush 530 are collected in the trash can portionvia ducting and hoses, entering a collection bin 150. FIG. 25B depictsalternative or combinable variations: a variation in which thecollection bin 150 is a smaller bin accessible by opening the trash canlid 1212 (i.e., proximate the lid 1212); and a variation in which thecollection bin 150 is replaced by or auxiliary to a container orreceptacle for ordinary bin liners 150A or, e.g., 30 liter kitchen bags.In either variation (and generally herein as a replacement for avacuum-bag or filter vacuum system), a cyclonic or other circulatorybagless vacuuming system that diverts debris using centripetalacceleration of debris may be used to divert the debris from the vacuumfilter or flow. In each case, the smaller collection bin 150 mayperiodically (by timer, and/or full status as measured by a capacitysensor; and or every time the trash can lid 1212 is opened) be emptiedinto the main bin line 150, e.g., by opening a panel or door with asolenoid, motor, clutch, linkage to the lid 1212 and driven by liftingthe lid 1212, or other actuator. As discussed herein, the collection bin150 may be a vacuum bin, and include a vacuum filter 910 removable withthe bin or removable separately from the trash can portion 1210 and isevacuated by a vacuum motor 900 in the maintenance station 100/trash canportion 1210. In the configuration shown in FIG. 25B, the vacuum 900 isa high powered vacuum (e.g., 6-12 amp) that pulls air through the filter910 and via the collection bin 150, through ducting and hoses along orwithin the trash can portion 1210, over and through the brush 530, andoptionally directly or diverted from the cleaning bin 30 of the robot10. Optionally, the remaining areas of the robot 10 (e.g., circuit boardareas) may benefit from evacuation as well, and are not sealed from thevacuum.

FIGS. 26A-26B illustrate an example of a wall mounted maintenancestation 1300 to which the robot 10 docks for bin evacuation. The wallmounted maintenance station 1300 may be connected to a central vacuumsystem of a house or stand alone with a station bin 1350. A door 1312pivotally attached to a station housing 1310 provides access to interiorportions of the station housing 1310, which may house the station bin1350 (if not connected to a central vacuum system), hoses, and vacuumattachments.

FIGS. 27A-27C illustrate an example where an upright vacuum cleaner 1400is configured to evacuate the robot bin 50. The upright vacuum cleaner1400 includes a vacuum head 1410 configured to mate with the robot bin50 for evacuation of the bin 50. In such a case, the robot 10 may followa platform 122 into a maintenance station 100 that receives the upright1400 (in this case, the maintenance station 100 may also be whollyenclosed in or part of the upright 1400). Once within or engaged withthe maintenance station 100, the panel 55 is moved aside to expose atleast the primary brush 60 (to expose any brushes which may accumulatefilaments or fuzz, including bristle type brushes). The maintenancestation/upright 1400 may lower, or locate in predetermined positions,brush-cleaning brush or beater 530. The brush cleaning member/mechanism530, in this case the upright's main cleaning brush or beater, engagesthe primary cleaning brush 65 of the robot 10, and is driven by a motor(not shown) in the maintenance station 100/upright 1400, the same motorusually used to rotate the brush cleaning member 530 in its role as themain beater or cleaning brush of the upright 1400. The debris orfilaments agitated by the brush cleaning brush 530 are collected in theupright via ducting and hoses, entering the collection bin 150 in themaintenance station 100/upright 1400, in this case the collection bin150 being the same as the main cleaning bin of the upright. As discussedherein, the collection bin 150 may be a vacuum bin, and include a vacuumfilter 910 removable with the bin or removable separately from theupright 1400 and is evacuated by a vacuum motor 900 in the maintenancestation 100. In the configuration shown in FIG. 27C, the vacuum 900 is ahigh powered vacuum (e.g., 6-12 amp) that pulls air through the filter910 and via the collection bin 150, through ducting and hoses along orwithin the upright handle and cleaning head assembly, over and throughthe brush 530, and optionally directly or diverted from the cleaning bin30 of the robot 10. Optionally, the remaining areas of the robot 10(e.g., circuit board areas) may benefit from evacuation as well, and arenot sealed from the vacuum.

Other details and features combinable with those described herein may befound in the following U.S. patent applications filed concurrentlyherewith, entitled “COVERAGE ROBOTS AND ASSOCIATED CLEANING BINS” havingassigned Ser. No. 11/751,267; and “CLEANING ROBOT ROLLER PROCESSING”having assigned Ser. No. 11/751,413, the entire contents of theaforementioned applications are hereby incorporated by reference.

A number of implementations have been described. Nevertheless, it willbe understood that various modifications may be made without departingfrom the spirit and scope of the disclosure. Accordingly, otherimplementations are within the scope of the following claims.

1-15. (canceled)
 16. A cleaning system comprising: a maintenance stationcomprising a cleaner interface configured to receive a robotic cleaner,a vacuum interface, and one or more electrical contacts configured tocause production of a signal when the robotic cleaner is received by thecleaner interface; and a handheld vacuum configured to be removablysecured to the maintenance station via the vacuum interface, thehandheld vacuum comprising a vacuum motor configured to produce anairflow through an evacuation assembly of the maintenance station toremove debris from a debris bin of the robotic cleaner when the handheldvacuum is attached to the maintenance station and when the roboticcleaner is received by the cleaner interface of the maintenance station,and draw air through an opening of the handheld vacuum when the handheldvacuum is not attached to the maintenance station.
 17. The cleaningsystem of claim 16, wherein an evacuation port assembly of the roboticcleaner is configured to mate with the evacuation assembly of themaintenance station when the robotic cleaner is received by the cleanerinterface of the maintenance station.
 18. The cleaning system of claim17, wherein the evacuation assembly of the maintenance station comprisesone or more evacuation ports configured to mate with correspondingevacuation ports of the evacuation port assembly of the robotic cleanerwhen the robotic cleaner is received by the cleaner interface of themaintenance station.
 19. The cleaning system of claim 16, wherein theairflow produced by the handheld vacuum (i) removes debris from thedebris bin of the robotic cleaner through a first set of evacuationports and (ii) causes air to be drawn into the debris bin of the roboticcleaner through a second set of ports.
 20. The cleaning system of claim16, wherein the evacuation assembly of the maintenance station isconfigured to form a substantially air-tight seal between themaintenance station and the robotic cleaner when the robotic cleaner isreceived by the cleaner interface of the maintenance station.
 21. Thecleaning system of claim 16, wherein the evacuation assembly of themaintenance station is configured to disengage a port cover of therobotic cleaner when the robotic cleaner is received by the cleanerinterface of the maintenance station.
 22. The cleaning system of claim16, wherein the opening of the handheld vacuum comprises a cleaning hoseand/or a cleaning head.
 23. The cleaning system of claim 16, wherein thehandheld vacuum comprises one or more vacuum attachments, and whereinthe maintenance station comprises a receptacle for receiving the vacuumattachments.
 24. The cleaning system of claim 16, wherein the handheldvacuum is configured to store the debris removed from the debris bin ofthe robotic cleaner.
 25. The cleaning system of claim 16, wherein themaintenance station is configured to charge a battery of the roboticcleaner when the robotic cleaner is received by the cleaner interface ofthe maintenance station.
 26. The cleaning system of claim 16, whereinthe maintenance station is configured to provide a control signal tocause the robotic cleaner to initiate a cleaning operation.
 27. Thecleaning system of claim 16, wherein the handheld vacuum is configuredto automatically produce the airflow through the evacuation assembly ofthe maintenance station when the robotic cleaner is received by thecleaner interface of the maintenance station.
 28. The cleaning system ofclaim 16, wherein the handheld vacuum is configured to produce theairflow through the evacuation assembly of the maintenance station inresponse to manual control by an operator.
 29. The cleaning system ofclaim 16, wherein the maintenance station comprises a station bin forstoring the debris removed from the debris bin of the robotic cleaner.30. The cleaning system of claim 29, wherein the station bin is separatefrom a cleaning bin of the handheld vacuum.
 31. The cleaning system ofclaim 16, wherein the cleaner interface of the maintenance station isconfigured to mate with a first side of the robotic cleaner, and the oneor more electrical contacts of the maintenance station are configured toalign with corresponding electrical contacts of the robotic cleaner, theelectrical contacts of the robotic cleaner located on a second side ofthe robotic cleaner.